Process for producing emulsion and microcapsules and apparatus therefor

ABSTRACT

A process and apparatus for rapidly producing an emulsion and microcapsules in a simple manner. A dispersion phase is ejected from a dispersion phase-feeding port toward a continuous phase flowing in a microchannel such that flows of the dispersion phase and the continuous phase cross each other, thereby obtaining microdroplets, formed by the shear force of the continuous phase, having a size smaller than the width of the channel for feeding the dispersion phase.

TECHNICAL FIELD

The present invention relates to a process and apparatus for producing amicroemulsion and microcapsules in water, oil, and chemically inertliquid.

BACKGROUND ART

Conventionally, apparatuses for producing a microemulsion (containingmicrospheres) and microcapsules have been used in steps of manufacturingchemicals and some processes have been proposed. There are the followingprocesses (see, for example, PCT Japanese Translation Patent ApplicationPublication No. 8-508933): a process in which a second solution isdropped in a first solution, a process in which a first solution isdropped in the air from the inside portion of a double tube and a secondsolution is dropped from the outside portion thereof, and so on. Amongprocesses for scattering droplets in the air, there is a process forejecting droplets using piezoelectric elements used for inkjet printersand so on.

On the other hand, a technique in which monodispersed microdroplets areprepared with laboratory equipment is disclosed in Japanese UnexaminedPatent Application Publication No. 2000-84384. However, in thistechnique, there is a problem in that the rate of preparing suchmicrodroplets is low and the microdroplets cannot be covered withsurfactants or microcapsule shells. Furthermore, only microdropletshaving a diameter three times larger than the width of microchannels canbe prepared.

SUMMARY OF THE INVENTION

In view of the above situation, it is an object of the present inventionto provide a process and apparatus for rapidly producing an emulsion andmicrocapsules in a simple manner.

In order to achieve the above object, the present invention provides thefollowing methods and apparatuses.

(1) A process for producing an emulsion includes a step of ejecting adispersion phase from a dispersion phase-feeding port toward acontinuous phase flowing in a microchannel in such a manner that flowsof the dispersion phase and the continuous phase cross each other,whereby microdroplets are formed by the shear force of the continuousphase and the size of the microdroplets is controlled.

(2) A process for producing microcapsules includes a step of feeding ashell-forming phase and a content-forming phase to a continuous phaseflowing in a microchannel, in such a manner that flows of theshell-forming phase and the content-forming phase join the flow of thecontinuous phase, to obtain microcapsules, wherein the shell-formingphase is fed from positions upstream to positions for feeding thecontent-forming phase in such a manner that the shell-forming phaseforms a thin layer.

(3) A process for producing an emulsion includes a step of ejecting adispersion phase toward the junction of flows of continuous phasesflowing in microchannels extending in the directions opposite to eachother, in such a manner that the flow of the dispersion phase joins theflows of the continuous phases, to obtain microdroplets.

(4) A process for producing microcapsules includes a step of feeding acontent-forming phase to first and second continuous phases flowing infirst and second microchannels extending in the directions opposite toeach other, in such a manner that the flow of the content-forming phasejoins the flows of the first and second continuous phases, to formmicrodroplets for forming contents; and then feeding a shell-formingphase to third and fourth continuous phases flowing in third and fourthmicrochannels, in such a manner that the flow of the shell-forming phasejoins the junction of flows of the third and fourth continuous phases,to form microdroplets for forming shells to obtain microcapsules.

(5) A process for producing an emulsion includes a step of allowingflows of a first continuous phase and a dispersion phase to jointogether at a first junction to form a two-phase flow and then allowingthe two-phase flow, consisting of the flows of the first continuousphase and the dispersion phase joined together, to join a flow of asecond continuous phase at a second junction to form an emulsioncontaining the dispersion phase.

(6) A process for producing microcapsules includes a step of allowingflows of a first continuous phase and a dispersion phase to jointogether at a first junction to form microdroplets and then allowing theflow of the first continuous phase containing the microdroplets to joina flow of a second continuous phase at a second junction to formmicrocapsules containing the first continuous phase containing themicrocapsules.

(7) An apparatus for producing an emulsion includes means for forming acontinuous phase flowing in a microchannel, means for feeding adispersion phase to the continuous phase in such a manner that flows ofthe continuous phase and the dispersion phase cross each other,dispersion phase-ejecting means for ejecting the dispersion phase from adispersion phase-feeding port, and means for forming microdroplets bythe shear force of the continuous phase to control the size of themicrodroplets.

(8) An apparatus for producing microcapsules includes means for forminga continuous phase flowing in a microchannel, means for feeding ashell-forming phase and a content-forming phase to a dispersion phase insuch a manner that flows of the shell-forming phase and content-formingphase join the flow of the continuous phase, and means for feeding theshell-forming phase from positions upstream to positions for feeding thecontent-forming phase in such a manner that shell-forming phase forms athin layer.

(9) An apparatus for producing an emulsion includes means for formingcontinuous phases flowing in microchannels extending in the directionsopposite to each other; and means for ejecting a dispersion phase towardthe junction of flows of the continuous phases, in such a manner thatthe flow of the dispersion phase joins the flows of the continuousphases, to obtain microdroplets.

(10) An apparatus for producing microcapsules includes means for feedinga content-forming phase to first and second continuous phases flowing infirst and second microchannels extending in the directions opposite toeach other, in such a manner that the flow of the content-forming phasejoins the flows of the first and second continuous phases, to formmicrodroplets for forming contents; and then feeding a shell-formingphase to third and fourth continuous phases flowing in third and fourthmicrochannels, in such a manner that the flow of the shell-forming phasejoins the junction of flows of the third and fourth continuous phases,to form coatings for forming shells to obtain microcapsules.

(11) In the emulsion-producing apparatus described in the above article(7) or (9), the means for feeding a plurality of the dispersion phaseseach include a substrate, a driven plate, an elastic member disposedbetween the substrate and the driven plate, and an actuator for drivingthe driven plate and thereby a plurality of the dispersion phases arefed at the same time.

(12) In the microcapsule-producing apparatus described in the abovearticle (8) or (10), the means for feeding a plurality of shell-formingphases and content-forming phases each include a substrate, a drivenplate, an elastic member disposed between the substrate and the drivenplate, and an actuator for driving the driven plate, and thereby aplurality of the shell-forming phases and content-forming phases are fedat the same time.

(13) The emulsion-producing apparatus described in the above article (7)or (9) further includes films, disposed on portions of inner wallsurfaces of the microchannel in which the continuous phase flows and thechannel for feeding the dispersion phase, for readily forming themicrodroplets, wherein the portions include the junction of the flows ofthe continuous phase and the dispersion phase and the vicinity of thejunction.

(14) The microcapsule-producing apparatus described in the above article(8) or (10) further includes films, disposed on portions of inner wallsurfaces of the microchannel in which the continuous phase flows and thechannel for feeding the dispersion phase, for readily forming themicrodroplets, wherein the portions include the junction of the flows ofthe continuous phase and the dispersion phase and the vicinity of thejunction.

(15) An apparatus for producing an emulsion includes a substrate havingparallel electrodes and a microchannel disposed on the substrate,wherein a dispersion phase disposed at the upstream side of themicrochannel is attracted and then ejected by a moving electric field,applied to the parallel electrodes, to form the emulsion.

(16) In the emulsion-producing apparatus described in the above article(15), the arrangement of the parallel electrodes disposed at the sideclose to the continuous phase is changed, whereby the formed emulsion isguided in a predetermined direction.

(17) In the emulsion-producing apparatus described in the above article(15), the moving speed of the moving electric field applied to theparallel electrodes is varied, whereby the forming rate of the emulsionis varied.

(18) An apparatus for producing an emulsion includes an elastic memberdisposed between rigid members, placed at a lower section of a liquidchamber for a dispersion phase, having a plurality of microchannelstherein; an actuator for applying a stress to the elastic member; and acontinuous phase communicatively connected to a plurality of themicrochannels.

(19) In the emulsion-producing apparatus described in the above article(18), a plurality of the microchannels each have a section, of which thediameter is decreased, having a tapered portion.

(20) In the emulsion-producing apparatus described in the above article(18), a plurality of the microchannels are provided, each of which havea lower section, of which the diameter is decreased, and having a firsttapered portion and also each have having a protrusion having a secondtapered portion for increasing the diameter of a further lower section.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a plan view showing a microdroplet-producing apparatusaccording to a first embodiment of the present invention.

FIG. 2 is an illustration showing microdroplet-producing processesaccording to the first embodiment of the present invention.

FIG. 3 is a plan view showing a microcapsule-producing apparatusaccording to a second embodiment of the present invention.

FIG. 4 is an illustration showing a microcapsule-producing processaccording to the second embodiment of the present invention.

FIG. 5 is a plan view showing a microdroplet-producing apparatusaccording to a third embodiment of the present invention.

FIG. 6 is an illustration showing a microdroplet-producing processaccording to the third embodiment of the present invention.

FIG. 7 is a plan view showing a microcapsule-producing apparatusaccording to a fourth embodiment of the present invention.

FIG. 8 is an illustration showing a microcapsule-producing processaccording to the fourth embodiment of the present invention.

FIG. 9 is an illustration showing the particle size obtained by varyingthe height of the continuous phases and dispersion phases in the fourthembodiment of the present invention.

FIG. 10 is an illustration showing a mechanism for ejecting a dispersionphase, a shell-forming phase, or a content-forming phase placed in amicrodroplet-producing apparatus according to a fifth embodiment of thepresent invention.

FIG. 11 is an illustration showing a mechanism for ejecting a dispersionphase, a shell-forming phase, or a content-forming phase placed in amicrodroplet-producing apparatus according to a sixth embodiment of thepresent invention.

FIG. 12 is an illustration showing a mechanism for ejecting a dispersionphase, a shell-forming phase, or a content-forming phase placed in amicrodroplet-producing apparatus according to a seventh embodiment ofthe present invention.

FIG. 13 is an illustration showing a mechanism for opening or closing adispersion phase-feeding port of a microdroplet-producing apparatusaccording to an eighth embodiment of the present invention.

FIG. 14 is an illustration showing a mechanism for opening or closing adispersion phase-feeding port of a microdroplet-producing apparatusaccording to a ninth embodiment of the present invention.

FIG. 15 is an illustration showing a mechanism for opening or closing adispersion phase-feeding port of a microdroplet-producing apparatusaccording to a tenth embodiment of the present invention.

FIG. 16 is a plan view showing an emulsion-producing apparatus accordingto an eleventh embodiment of the present invention.

FIG. 17 is a plan view showing an emulsion-producing apparatus accordingto a twelfth embodiment of the present invention.

FIG. 18 is an illustration showing an emulsion-forming apparatusaccording to a thirteenth embodiment of the present invention.

FIG. 19 is an illustration showing a microcapsule-forming apparatusaccording to a fourteenth embodiment of the present invention.

FIG. 20 is an illustration showing a configuration of an apparatus forforming a large amount of microdroplets using the elastic deformation ofrubber.

FIG. 21 is an illustration showing the operation of a first apparatus,shown in FIG. 20, for forming a large amount of microdroplets.

FIG. 22 is an illustration showing the operation of a second apparatus,shown in FIG. 20, for forming a large amount of microdroplets.

FIG. 23 is an illustration showing the operation of a third apparatus,shown in FIG. 20, for forming a large amount of microdroplets.

BEST MODE FOR CARRYING OUT THE INVENTION

Embodiments of the present invention will now be described in detail.

FIG. 1 is a plan view showing an apparatus for producing microdropletsaccording to a first embodiment of the present invention, and FIG. 2 isan illustration showing processes for producing such microdroplets. FIG.2( a) is an illustration showing a microdroplet-producing process (No.1), FIG. 2( b) is another illustration showing a microdroplet-producingprocess (No. 2), FIG. 2( b-1) is a fragmentary sectional view thereof,and FIG. 2( b-2) is the sectional view of FIG. 2( b-1) taken along theline A-A.

In these figures, reference numeral 1 represents a main body of themicrodroplet-producing apparatus, reference numeral 2 represents amicrochannel in which a continuous phase flows and which is disposed inthe main body 1, reference numeral 3 represents a dispersionphase-feeding channel placed such that the dispersion phase-feedingchannel 3 and the microchannel 2 cross, reference numeral 4 represents adispersion phase-feeding port, reference numeral 5 represents thecontinuous phase (for example, oil), reference numeral 6 represents adispersion phase (for example, water), reference numeral 7 represents amicrodroplet, and reference numeral 8 represents a hydrophobic film.

In the above configuration, the dispersion phase 6 is fed to thecontinuous phase 5 flowing in the microchannel 2 in such a manner thatflows of the dispersion phase 6 and the continuous phase 5 cross eachother, as shown in FIG. 2. Part of the continuous phase 5 extendsthrough each dispersion phase-feeding port 4, thereby producing themicrodroplets 7 having a diameter smaller than the width of thedispersion phase-feeding channel 3.

For example, microdroplets having a diameter of about 25 μm can beobtained when the pressure of the dispersion phase (water) 6 is set to2.45 kPa, the pressure of the continuous phase (oil containing 70% ofoleic acid) 5 is set to 4.85 kPa, and the microchannel 2 and thedispersion phase-feeding channel 3 have a width of 100 μm and a heightof 100 μm. When the pressure of the continuous phase is set to 5.03 kPa,microdroplets having a diameter of about 5 μm can be obtained.

As shown in FIGS. 2( b-1) and 2(b-2), in order to readily form themicrodroplets 7 (in order to readily repelling the microdroplets), thehydrophobic films 8 are preferably disposed on portions of the innerwalls of the microchannel 2, in which the continuous phase 5 flows, andthe dispersion phase-feeding channel 3, wherein the portions aredisposed at the vicinity of the junction of the flows of the continuousphase (for example, oil) 5 and the dispersion phase (for example, water)6.

In the above embodiment, since the continuous phase 5 contains oil andthe dispersion phase 6 contains water, the hydrophobic films 8 arepreferably used. However, when the continuous phase contains water andthe dispersion phase contains oil, hydrophilic films are preferablyused.

FIG. 3 is a plan view showing an apparatus for producing microcapsulesaccording to a second embodiment, and FIG. 4 is an illustration showinga process for producing such microcapsules.

In these figures, reference numeral 11 represents a main body of themicrocapsule-producing apparatus, reference numeral 12 represents amicrochannel in which a continuous phase flows and which is disposed inthe main body 11, reference numeral 13 represents a shell-formingphase-feeding channel placed such that the shell-forming phase-feedingchannel 13 and the microchannel 12 cross, reference numeral 14represents a content-forming phase-feeding channel placed such that thecontent-forming phase-feeding channel 14 and the microchannel 12 cross,reference numeral 15 represents a shell-forming phase-feeding port,reference numeral 16 represents a content-forming phase-feeding port,reference numeral 17 represents the continuous phase (for example,water), reference numeral 18 represents a shell-forming phase, referencenumeral 19 represents a content-forming phase, and reference numeral 20represents a microcapsule.

In the above configuration, the shell-forming phase 18 and thecontent-forming phase 19 are fed to the continuous phase 17 flowing inthe microchannel 12 in such a manner that flows of the shell-formingphase 18 and the content-forming phase 19 join the flow of thecontinuous phase 17, as shown in FIG. 4. The shell-forming phase 18 isfed from positions upstream to positions for feeding the content-formingphase 19 in such a manner that shell-forming phase 18 forms a thinlayer.

FIG. 5 is a plan view showing an apparatus for producing microdropletsaccording to a third embodiment, and FIG. 6 is an illustration showing aprocess for producing such microdroplets.

In these figures, reference numeral 21 represents a main body of themicrodroplet-producing apparatus, reference numeral 22 represents afirst microchannel, reference numeral 23 represents a secondmicrochannel, reference numeral 24 represents a first continuous phase,reference numeral 25 represents a second continuous phase, referencenumeral 26 represents the junction of flows of the first continuousphase 24 and the second continuous phase 25, reference numeral 27represents a dispersion phase-feeding channel, reference numeral 28represents a dispersion phase, and reference numeral 29 represents amicrodroplet.

In the above configuration, the dispersion phase 28 is ejected towardthe junction 26 of flows of the first continuous phase 24 and the secondcontinuous phase 25 flowing in the microchannels 22 and 23,respectively, in such a manner that the flow of the dispersion phase 28joins the flows of the first continuous phase 24 and the secondcontinuous phase 25, as shown in FIG. 6. Thereby, the microdroplets 29can be produced.

FIG. 7 is a plan view showing an apparatus for producing microcapsulesaccording to a fourth embodiment, and FIG. 8 is an illustration showinga process for producing such microcapsules.

In these figures, reference numeral 31 represents a main body of themicrocapsule-producing apparatus, reference numeral 32 represents afirst microchannel in which a continuous phase flows and which isdisposed in the main body 31, reference numeral 33 represents a secondmicrochannel in which another continuous phase flows and which isdisposed in the main body 31, reference numeral 34 represents a firstcontinuous phase (for example, oil), reference numeral 35 represents asecond continuous phase (for example, oil), reference numeral 36represents the junction of flows of the first continuous phase 34 andthe second continuous phase 35, reference numeral 37 represents acontent-forming phase-feeding channel, reference numeral 38 represents acontent-forming phase (for example, water), reference numeral 39represents a microdroplet (for example, water spheres), referencenumeral 40 represents a third microchannel in which another continuousphase flows and which is disposed in the main body 31, reference numeral41 represents a fourth microchannel in which another continuous phaseflows and which is disposed in the main body 31, reference numeral 42represents a third continuous phase (for example, water), referencenumeral 43 represents a fourth continuous phase (for example, water),reference numeral 44 represents the junction of flows of the thirdcontinuous phase 42 and the fourth continuous phase 43, referencenumeral 45 represents a shell-forming phase, reference numeral 46represents a shell-forming microdroplet, and reference numeral 47represents a microcapsule.

In the above configuration, the content-forming phase 38 is fed to thecontinuous phases 34 and 35 flowing in the first and secondmicrochannels 32 and 33, respectively, in such a manner that the flow ofthe content-forming phase 38 joins the flows of the continuous phases 34and 35. Thereby, the microdroplets 39 for forming contents are formed.

Subsequently, the shell-forming phase 45 containing the first and secondcontinuous phases 34 and 35 mixed together is fed to the continuousphases 42 and 43 flowing in the third and fourth microchannels 40 and 41in such a manner that the flow of the shell-forming phase 45 joins thejunction of the flows of the third and fourth continuous phases 42 and43. Thereby, a coating for forming a shell is formed on eachmicrodroplet 39 for forming a content, thereby forming each microcapsule47.

In this embodiment, the microcapsule 47 contains the single microdroplet39. However, the microcapsule 47 may contain a plurality of themicrodroplets 39.

FIG. 9 shows the particle size obtained by varying the height (which canbe converted into the pressure) of the continuous phases and dispersionphases, when the first and second microchannels 32 and 33 and thecontent-forming phase-feeding channel 37 have a width of 100 μm and aheight of 100 μm and the channel in which the microdroplets 39 arepresent have a width of 500 μm and a height of 100 μm. It is clear thatthe particle size can be controlled by varying the height (which can beconverted into the pressure) of the continuous phases and dispersionphases.

FIG. 10 is an illustration showing a mechanism for ejecting a dispersionphase, a shell-forming phase, or a content-forming phase placed in amicrodroplet-producing apparatus according to a fifth embodiment of thepresent invention. FIG. 10( a) is an illustration showing a situationwherein the piezoelectric actuators are expanded and therefore such aphase is not ejected, and FIG. 10( b) is an illustration showing asituation wherein the piezoelectric actuators are contracted to ejectthe phase.

In these figures, reference numeral 51 represents a substrate, referencenumeral 52 represents a driven plate, reference numeral 53 representsrubber, reference numeral 54 represents the piezoelectric actuators,each of which is disposed at the corresponding ends of the driven plate52, reference numerals 55 a-55 d represent a plurality of feeding ports,and reference numerals 56 a-56 d represent a plurality of channelsarranged for a single dispersion phase. A back pressure is applied tothe bottom portion of the dispersion phase.

In these figures, reference numeral 51 represents a substrate, referencenumeral 52 represents a driven plate, reference numeral 53 representsrubber, reference numeral 54 represents the piezoelectric actuators eachdisposed at the corresponding ends of the driven plate 52, referencenumerals 55 a-55 d represent a plurality of feeding ports, and referencenumerals 56 a-56 d represent a plurality of channels arranged for asingle dispersion phase. A back pressure is applied to the bottomportion of the dispersion phase.

As shown in FIG. 10( a), a plurality of the channels 56 a-56 d arearranged, and the dispersion phase can be ejected therefrom at the sametime when the piezoelectric actuators 54 are contracted, as shown inFIG. 10( b).

Various actuators may be used instead of the above piezoelectricactuators.

FIG. 11 is an illustration showing a mechanism for ejecting a dispersionphase, a shell-forming phase, or a content-forming phase placed in amicrodroplet-producing apparatus according to a sixth embodiment of thepresent invention. FIG. 11( a) is an illustration showing such asituation that a bimorph actuator is not warped and therefore such aphase is not ejected, and FIG. 11( b) is an illustration showing such asituation that the bimorph actuator is warped, thereby ejecting thephase.

In these figures, reference numeral 61 represents the bimorph actuator,reference numeral 62 represents a fixed plate, reference numeral 63represents rubber, reference numerals 64 a-64 d represent a plurality offeeding ports, and reference numerals 65 a-65 d represent a plurality ofchannels arranged for a single dispersion phase. A back pressure isapplied to the bottom portion of the dispersion phase.

As shown in FIG. 11( a), a plurality of the channels 65 a-65 d arearranged, and the dispersion phase can be ejected therefrom at the sametime by the operation (upward warping) of the bimorph actuator 61, asshown in FIG. 11( b).

FIG. 12 is an illustration showing a mechanism for ejecting a dispersionphase, a shell-forming phase, or a content-forming phase placed in amicrodroplet-producing apparatus according to a seventh embodiment ofthe present invention. FIG. 12( a) is an illustration showing asituation wherein an electrostrictive polymer is not energized andtherefore such a phase is not ejected, and FIG. 12( b) is anillustration showing a situation wherein the electrostrictive polymer isenergized (contracted), thereby ejecting the phase.

In these figures, reference numeral 71 represents a substrate, referencenumeral 72 represents a driven plate, reference numeral 73 representsthe electrostrictive polymer, reference numerals 74 a-74 d represent aplurality of feeding ports, and reference numerals 75 a-75 d represent aplurality of channels arranged for a single dispersion phase. A backpressure is applied to the bottom portion of the dispersion phase.

As shown in FIG. 12( a), a plurality of the channels 75 a-75 d arearranged, and the dispersion phase can be ejected therefrom at the sametime by the operation (contraction) of the electrostrictive polymer 73,as shown in FIG. 12( b).

FIG. 13 is an illustration showing a mechanism for opening or closing adispersion phase-feeding port of a microdroplet-producing apparatusaccording to an eighth embodiment of the present invention. FIG. 13( a)is an illustration showing a situation wherein piezoelectric actuatorsare not energized (contracted) and therefore gates for a phase areopened, and FIG. 13( b) is an illustration showing a situation whereinpiezoelectric actuators are energized (expanded) and thereby the gatesfor the phase are closed.

In these figures, reference numeral 81 represents a substrate, referencenumeral 82 represents rubber, reference numeral 83 represents a drivenplate, reference numeral 84 represents the piezoelectric actuators,reference numeral 85 represent a fixed plate, and reference numerals 86a-86 d represent a plurality of the gates.

As shown in these figures, a plurality of the gates 86 a-86 d arearranged, and all the gates for the phase can be closed by the operationof the two piezoelectric actuators 84 disposed at both sides.

Various actuators may be used instead of the above actuators.

FIG. 14 is an illustration showing a mechanism for opening or closing adispersion phase-feeding port of a microdroplet-producing apparatusaccording to a ninth embodiment of the present invention. FIG. 14( a) isan illustration showing a situation wherein a bimorph actuator is notenergized (not warped) and therefore gates for a phase are opened, andFIG. 14( b) is an illustration showing such a situation that the bimorphactuator is energized (warped downward) and thereby the gates for thephase are closed.

In these figures, reference numeral 91 represents a substrate, referencenumeral 92 represents rubber, reference numeral 93 represents thebimorph actuator, and reference numerals 94 a-94 d represent a pluralityof the gates.

As shown in these figures, a plurality of the gates 94 a-94 d arearranged, and all the gates can be closed at the same time by theoperation of the bimorph actuator 93.

FIG. 15 is an illustration showing a mechanism for opening or closing adispersion phase-feeding port of a microdroplet-producing apparatusaccording to a tenth embodiment of the present invention. FIG. 15( a) isan illustration showing a situation wherein an electrostrictive polymeris not energized and therefore the gates for a phase are opened, andFIG. 15( b) is an illustration showing such a situation that theelectrostrictive polymer is energized (contracted) and thereby the gatesfor the phase are closed.

In these figures, reference numeral 101 represents a substrate,reference numeral 102 represents a driven plate, reference numeral 103represents the electrostrictive polymer, and reference numerals 104a-104 d represent a plurality of the gates.

As shown in FIG. 15( a), a plurality of the gates 104 a-104 d are openedwhen the electrostrictive polymer 103 is not energized (expanded). Asshown in FIG. 15( b), a plurality of the gates 104 a-104 d are closed atthe same time when the electrostrictive polymer 103 is energized(contracted).

FIG. 16 is a plan view showing an emulsion-producing apparatus accordingto an eleventh embodiment of the present invention. FIG. 16( a) is aplan view showing the emulsion-producing apparatus to which a dispersionphase has not been introduced yet, FIG. 16( b) is a plan view showingthe emulsion-producing apparatus to which liquid has been charged, andFIG. 16( c) is an illustration showing such a situation that a largedroplet is set for the emulsion-producing apparatus and microdroplets(emulsion) are produced due to a moving electric field induced by staticelectricity.

In these figures, reference numeral 111 represents a substrate,reference numeral 112 represents electrodes disposed on the substrate111, reference numeral 113 represents a microchannel disposed above thesubstrate 111 having the electrodes 112 thereon, reference numeral 114represents a dispersion phase, and reference numeral 115 represents anemulsion formed by causing the dispersion phase 114 to pass through themicrochannel 113.

In this embodiment, the electrodes 112 are arranged to be perpendicularto the microchannel 113, and a moving electric field is applied to theelectrodes 112, thereby forming the emulsion 115. The emulsion 115 isguided in the direction perpendicular to the electrodes (in the downwarddirection herein) depending on the moving electric field induced by thestatic electricity applied to the electrodes 112.

The rate of forming the microdroplets can be changed by varying themoving speed of the moving electric field.

FIG. 17 is a plan view showing an emulsion-producing apparatus accordingto a twelfth embodiment of the present invention. FIG. 17( a) is a planview showing the emulsion-producing apparatus to which a dispersionphase has not been introduced yet, and FIG. 17( b) is an illustrationshowing such a situation that the dispersion phase is introduced to theemulsion-producing apparatus, thereby forming an emulsion.

In these figures, reference numeral 121 represents a substrate,reference numeral 122 represents electrodes disposed on the substrate121, reference numeral 123 represents a microchannel disposed above thesubstrate 121 having the electrodes 122 thereon, reference numeral 124represents a dispersion phase, and reference numeral 125 represents anemulsion formed by causing the dispersion phase 124 to pass through themicrochannel 123.

In this embodiment, on the exit side of the microchannel 123, theelectrodes 122 are vertically arranged and thereby the formed emulsion125 is guided in the horizontal direction depending on a staticelectricity applied to the electrodes 122.

FIG. 18 is an illustration showing an emulsion-forming apparatusaccording to a thirteenth embodiment of the present invention. FIG. 18(a) is a schematic view showing the total configuration of themonodispersed emulsion-forming apparatus, and FIG. 18( a-1) is the leftside elevational view thereof, FIG. 18( a-2) is a schematic plan viewthereof, FIG. 18( a-3) is the right side elevational view thereof. FIG.18( b) is an illustration showing a first junction, and FIG. 18(C) is anillustration showing a second junction.

In these figures, reference numeral 131 represents a main body of theemulsion-forming apparatus, reference numeral 132 represents amicrochannel in which a dispersion phase flows, reference numeral 133represents a microchannel in which a first continuous phase flows,reference numeral 134 represents a microchannel in which a secondcontinuous phase flows, reference numeral 135 represents the firstjunction at which flows of the dispersion phase and the first continuousphase are joined together, reference numeral 136 represents the secondjunction at which flows of the dispersion phase, the first continuousphase, and the second continuous phase are joined together, referencenumeral 137 represents the first continuous phase, reference numeral 138represents the dispersion phase, reference numeral 139 represents thesecond continuous phase, and reference numeral 140 represents a formedemulsion.

In this embodiment, the flows of the dispersion phase 138 and the firstcontinuous phase 137 are joined together at the first junction 135,thereby forming a two-phase flow containing the first continuous phase137 and the dispersion phase 138. At the second junction 136, a flow ofthe second continuous phase 139 and the two-phase flow containing thefirst continuous phase 137 and the dispersion phase 138 are joinedtogether, and thereby the emulsion 140 is formed from the dispersionphase 138.

According to this embodiment, there is an advantage in that an emulsionhaving a size smaller than the width of channels can be readily formed.

FIG. 19 is an illustration showing a microcapsule-forming apparatusaccording to a fourteenth embodiment of the present invention. FIG. 19(a) is a schematic view showing the total configuration of themicrocapsule-forming apparatus, and FIG. 19( a-1) is the left sideelevational view thereof, FIG. 19( a-2) is a schematic plan viewthereof, FIG. 19( a-3) is the right side elevational view thereof. FIG.19( b) is an illustration showing a first junction, and FIG. 19(C) is anillustration showing a second junction.

In these figures, reference numeral 141 represents a main body of themicrocapsule-forming apparatus, reference numeral 142 represents amicrochannel in which a dispersion phase (for example, water) flows,reference numeral 143 represents a microchannel in which a firstcontinuous phase (for example, oil) flows, reference numeral 144represents a microchannel in which a second continuous phase (forexample, water) flows, reference numeral 145 represents the firstjunction at which flows of the dispersion phase and the first continuousphase are joined together, reference numeral 146 represents the secondjunction at which flows of the dispersion phase, the first continuousphase, and the second continuous phase are joined together, referencenumeral 147 represents the first continuous phase, reference numeral 148represents the dispersion phase, reference numeral 149 represents anemulsion (for example, water), reference numeral 150 represents thesecond continuous phase, and reference numeral 151 represents formedmicrocapsules. The microcapsules 151 can contain one or more emulsions149.

FIG. 20 is an illustration showing a configuration of an apparatus ofthe present invention, wherein the apparatus can be used for forming alarge amount of microdroplets (emulsion/microcapsules) using the elasticdeformation of rubber. FIG. 21 is an illustration showing the operationof a first forming apparatus therefor.

In these figures, reference numeral 160 represents a linear motor,reference numeral 161 represents a liquid chamber, reference numeral 162represents a cover, reference numeral 163 represents a dispersion phase,reference numeral 164 represents an upper stainless plate, referencenumeral 165 represents a rubber member, reference numeral 166 representsa lower stainless plate, reference numeral 167 represents microchannels,reference numeral 168 represents a continuous phase, and referencenumeral 169 represents a formed emulsion (microdroplets). Anotheractuator including a piezoelectric actuator may be used instead of thelinear motor 160 functioning as an actuator.

When the linear motor 160 is operated to apply a pressure to the liquidchamber 161 (see FIG. 21( a)), to which a back pressure is applied, fromabove, the rubber member 165 disposed between the upper stainless plate164 and the lower stainless plate 166 is pressed (see FIG. 21( b)) andthereby part of the dispersion phase 163 is separated and then ejectedfrom each microchannel 167, thereby forming the microdroplets 169. Inthis configuration, since a large number of the microchannels 167 extendthrough the upper stainless plate 164, the rubber member 165, and thelower stainless plate 166, a large amount of the microdroplets 169 canbe readily produced by the operation of the linear motor 160 at a time.

FIG. 22 is an illustration showing the operation of a second apparatus,shown in FIG. 20, for forming a large amount of microdroplets.

In this embodiment, a plurality of the microchannels 167 each have anarrow section 167B having a tapered portion 167A formed by narrowing alower channel portion.

When the linear motor 160 is operated to apply a pressure to the liquidchamber 161 (see FIG. 22( a)), to which a back pressure is applied, fromabove, the rubber member 165 disposed between the upper stainless plate164 and the lower stainless plate 166 is pressed from above (see FIG.22( b)) and thereby part of the dispersion phase 163 is separated andthen ejected from each microchannel 167, thereby forming themicrodroplets 169. In this configuration, since each microchannel 167has the narrow lower portion having each tapered portion 167A, themicrodroplets 169 can be efficiently ejected in the downward direction.

FIG. 23 is an illustration showing the operation of a third apparatus,shown in FIG. 20, for forming a large amount of microdroplets.

In this embodiment, a plurality of the microchannels 167 each have anarrow section 167E that has a first tapered portion 167C formed bynarrowing a lower channel portion and a second tapered portion 167Dformed by expanding a further lower channel portion.

When the linear motor 160 is operated to apply a pressure to the liquidchamber 161 (see FIG. 23( a)), to which a back pressure is applied, fromabove, the rubber member 165 disposed between the upper stainless plate164 and the lower stainless plate 166 is pressed from above (see FIG.23( b)) and thereby part of the dispersion phase 163 is separated andthen ejected from each microchannel 167, thereby forming microdroplets169′. In this configuration, each microdroplet 169′ is separated at eachmicrochannel 167 having the first tapered portion 167C, and themicrodroplet 169′ formed by separating part of the dispersion phase isguided along the second tapered portion 167D in the downward directionand then efficiently ejected.

The present invention is not limited to the above embodiments, andvarious modifications may be performed within the scope of the presentinvention. The present invention covers such modifications.

As described above in detail, according to the present invention, anemulsion and microcapsules can be rapidly formed in a simple manner.

Furthermore, the formed emulsion can be guided in a predetermineddirection and the rate of forming the emulsion can be varied.

Furthermore, the emulsion can be produced in a large scale.

INDUSTRIAL APPLICABILITY

According to a process and apparatus for producing an emulsion andmicrocapsules according to the present invention, an emulsion andmicrocapsules can be rapidly formed in a simple manner. Such a processand apparatus are fit for the field of drug production andbiotechnology.

1. A process for producing an emulsion, comprising a step of ejecting adispersion phase flowing in a dispersion phase-feeding microchannel froma dispersion phase-feeding port toward a continuous phase flowing in amicrochannel in such a manner that flows of the dispersion phase and thecontinuous phase cross each other and part of the continuous phaseextends through the dispersion phase-feeding port, whereby microdropletsare formed by the shear force of the continuous phase, the microdropletshaving a diameter smaller than the width of the dispersion phase-feedingmicro-channel.
 2. A process for producing microcapsules, comprising thesteps of: feeding a first dispersion phase from a first dispersionphase-feeding micro-channel into a continuous phase flowing in amicrochannel at a first junction point in such a manner that thecontinuous phase flows as a layer and the first dispersion phase flowsas another layer, thereby forming a two-layered flow; and feeding asecond dispersion phase from a second dispersion phase-feedingmicro-channel into the flow of the first dispersion phase in thetwo-layered flow at a second junction point, whereby microcapsules areformed in the continuous phase, the microcapsules including the seconddispersion phase encapsulated by the first dispersion phase as shells.3. An apparatus for producing an emulsion, comprising: a main body; amicrochannel formed in the main body, within which a continuous phaseflows; a dispersion phase-feeding micro-channel formed in the main bodyin a direction to cross the microchannel, the dispersion phase-feedingmicro-channel including a dispersion phase-feeding port; means forfeeding a dispersion phase from the dispersion phase-feeding port to thecontinuous phase in such a manner that flows of the continuous and thedispersion phase cross each other, the dispersion phase-feeding porthaving a same width as that of the dispersion phase-feedingmicro-channel; and means for forming microdroplets, whereby part of thecontinuous phase extends through the dispersion phase-feeding port, andmicrodroplets may be formed by the shear force of the continuous phase,the microdroplets having a diameter smaller than the width of thedispersion phase-feeding micro-channel.
 4. The apparatus for producingan emulsion according to claim 3 further comprising films, disposed onportions of inner wall surfaces of the microchannel in which thecontinuous phase flows and the micro-channel for feeding the dispersionphase, for readily forming the microdroplets, wherein the portionsinclude the junction of the flows of the continuous phase and thedispersion phase and the vicinity of the junction.
 5. An apparatus forproducing microcapsules, comprising: a main body; a microchannel formedin the main body, wherein a continuous phase flows; a first dispersionphase-feeding micro-channel formed in the main body in direction tocross the microchannel, the first dispersion phase-feeding micro-channelincluding a first dispersion phase-feeding port to feed a firstdispersion phase, wherein the continuous phase in the microchannel andthe first dispersion phase from the first dispersion phase-feedingmicro-channel form a two-layered flow at the first dispersionphase-feeding port; a second dispersion phase-feeding micro-channelformed in the main body in a direction to cross the microchannel, thesecond dispersion phase-feeding micro-channel including a seconddispersion phase-feeding port to feed a second dispersion phase, whereinthe second dispersion phase may be fed into the first dispersion phasein the two-layered flow at the second dispersion phase-feeding port; andmeans for forming microcapsules, whereby microcapsules are formed in thecontinuous phase, the microcapsules including the second dispersionphase encapsulated by the first dispersion phase as shells.
 6. Theapparatus for producing microcapsules according to claim 5 furthercomprising films, disposed on portions of inner wall surfaces of themicrochannel in which the continuous phase flows and the micro-channelfor feeding the first or second dispersion phase, for readily formingthe microdroplets, wherein the portions include the junction of theflows of the continuous phase and the first or second dispersion phaseand the vicinity of the junction.